2002 DODGE RAM ac compressor pag oil

8W-02 COMPONENT INDEX
Component Page
4WD Switch.......................... 8W-31
A/C Compressor Clutch Relay............ 8W-42
A/C Compressor Clutch................. 8W-42
A/C- Heater Control.................... 8W-42
A/C Heater Temperature Select........... 8W-42
A/C High Pressure Switch............... 8W-42
A/C Low Pressure Switch................ 8W-42
Accelerator Pedal Position Sensor......... 8W-30
Aftermarket Center High Mounted Stop
Lamp............................. 8W-51
Aftermarket Trailer Tow Connector........ 8W-54
Airbag Control Module.................. 8W-43
Ambient Temperature Sensor............ 8W-49
Ash Receiver Lamp.................... 8W-44
Automatic Day/Night Mirror............. 8W-49
Automatic Shut Down Relay............. 8W-30
Auxiliary Battery...................... 8W-20
Back-Up Lamp Switch.................. 8W-51
Back-Up Lamp........................ 8W-51
Battery Temperature Sensor............. 8W-30
Battery............................. 8W-20
Blend Door Actuator................... 8W-42
Blower Motor Relay.................... 8W-42
Blower Motor Resistor Block............. 8W-42
Blower Motor......................... 8W-42
Brake Lamp Switch.................... 8W-51
Brake Pressure Switch............... 8W-34, 35
Bypass Jumper....................... 8W-21
Camshaft Position Sensor............... 8W-30
Capacitor......................... 8W-10, 30
Cargo Lamps........................ 8W-44
Center High Mounted Stop Lamps........ 8W-51
Center Identification Lamp.............. 8W-50
Central Timer Module.................. 8W-45
Cigar Lighter......................... 8W-41
Circuit Breakers...................... 8W-12
Clockspring.................. 8W-33, 41, 43, 47
Clutch Pedal Position Switch............. 8W-21
Combination Flasher................... 8W-52
Controller Antilock Brake............ 8W-34, 35
Crankshaft Position Sensor.............. 8W-30
Cummins Bus........................ 8W-18
Cup Holder Lamp..................... 8W-44
Data Link Connector................... 8W-18
Daytime Running Lamp Module.......... 8W-50
Dome Lamp.......................... 8W-44
Driver Airbag......................... 8W-43
Driver Cylinder Lock Switch............. 8W-39
Driver Door Ajar Switch................ 8W-45
Driver Door Lock Motor................. 8W-61
Driver Door Window/Lock Switch...... 8W-60, 61
Driver Heated Seat Cushion............. 8W-63Component Page
Driver Heated Seat Switch.............. 8W-63
Driver Lumbar Motor.................. 8W-63
Driver Power Seat Front Vertical Motor.... 8W-63
Driver Power Seat Horizontal Motor....... 8W-63
Driver Power Seat Rear Vertical Motor..... 8W-63
Driver Power Seat Switch............... 8W-63
Driver Power Window Motor............. 8W-60
Electric Brake Provision................ 8W-54
Engine Control Module................. 8W-30
Engine Coolant Temperature Sensor....... 8W-30
Engine Oil Pressure Sensor.............. 8W-30
Engine Starter Motor Relay.............. 8W-21
Engine Starter Motor................... 8W-21
EVAP/Purge Solenoid................... 8W-30
Fender Lamp......................... 8W-51
Fog Lamp Relay....................... 8W-50
Fog Lamp............................ 8W-50
Fuel Heater Relay..................... 8W-30
Fuel Heater........................ 8W-30-36
Fuel Injection Pump................... 8W-30
Fuel Injectors......................... 8W-30
Fuel Pump Module.................... 8W-30
Fuel Pump Relay...................... 8W-30
Fuel Tank Module..................... 8W-30
Fuel Transfer Pump.................... 8W-30
Fuses (JB)........................... 8W-12
Fuses (PDC).......................... 8W-10
Fusible Link....................... 8W-20, 30
Grounds............................. 8W-15
Generator............................ 8W-20
Glove Box Lamp And Switch............. 8W-44
Headlamp Beam Select Switch........... 8W-50
Headlamp Switch...................... 8W-50
Headlamp........................... 8W-50
Heated Mirror Relay................... 8W-62
Heated Mirror Switch.................. 8W-62
Heated Seat Relay..................... 8W-12
High Note Horn....................... 8W-41
Horn Relay.......................... 8W-41
Horn Switch.......................... 8W-41
Idle Air Control Motor.................. 8W-30
Ignition Coils......................... 8W-30
Ignition Switch....................... 8W-10
Instrument Cluster.................... 8W-40
Intake Air Heater Relays................ 8W-30
Intake Air Heater..................... 8W-30
Intake Air Temperature Sensor........... 8W-30
Intermittent Wiper Switch............... 8W-53
Joint Connectors....... 8W-10, 12, 15, 30, 34, 35,
40, 44, 45, 51, 53, 54, 70
Junction Block........................ 8W-12
Leak Detection Pump.................. 8W-30
BR/BE8W-02 COMPONENT INDEX 8W - 02 - 1

8W-10 POWER DISTRIBUTION
Component Page
A/C Compressor Clutch................ 8W-10-27
A/C Compressor Clutch Relay......... 8W-10-9, 27
Aftermarket Center High Mounted Stop
Lamp........................... 8W-10-13
Aftermarket Trailer Tow Connector....... 8W-10-21
Automatic Shut Down Relay.......... 8W-10-14, 20
Auxiliary Battery..................... 8W-10-8
Battery............................. 8W-10-8
Blower Motor....................... 8W-10-23
Blower Motor Relay................. 8W-10-8, 23
Brake Lamp Switch................. 8W-10-8, 13
Capacitor.......................... 8W-10-16
Center High Mounted Stop Lamp No. 1.... 8W-10-13
Center High Mounted Stop Lamp No. 2.... 8W-10-13
Central Timer Module.............. 8W-10-22, 26
Circuit Breaker 2.................... 8W-10-10
Clockspring......................... 8W-10-26
Combination Flasher.................. 8W-10-13
Controller Antilock Brake.............. 8W-10-23
Daytime Running Lamp Module......... 8W-10-25
Electric Brake Provision............. 8W-10-13, 21
Engine Control Module................ 8W-10-12
Engine Starter Motor................. 8W-10-23
Engine Starter Motor Relay........... 8W-10-8, 23
Fog Lamp Relay..................... 8W-10-25
Fuel Heater........................ 8W-10-20
Fuel Heater Relay.................. 8W-10-8, 20
Fuel Injection Pump.................. 8W-10-12
Fuel Injector No. 1................. 8W-10-15, 16
Fuel Injector No. 2................. 8W-10-15, 16
Fuel Injector No. 3................. 8W-10-15, 16
Fuel Injector No. 4................. 8W-10-15, 16
Fuel Injector No. 5................. 8W-10-15, 16
Fuel Injector No. 6................. 8W-10-15, 16
Fuel Injector No. 7................. 8W-10-15, 16
Fuel Injector No. 8................. 8W-10-15, 16
Fuel Injector No. 9................... 8W-10-16
Fuel Injector No. 10................... 8W-10-16
Fuel Pump Module................... 8W-10-11
Fuel Pump Relay.................. 8W-10-11, 12
Fuse 1 (JB)......................... 8W-10-10
Fuse 1 (PDC)...................... 8W-10-8, 10
Fuse 2 (PDC)................... 8W-10-8, 10, 22
Fuse 3 (PDC)................... 8W-10-8, 11, 12
Fuse 4 (JB)......................... 8W-10-10
Fuse 4 (PDC)...................... 8W-10-8, 13
Fuse 5 (PDC)...................... 8W-10-8, 13
Fuse 6 (PDC)................... 8W-10-8, 14, 20
Fuse 7 (PDC)...................... 8W-10-8, 20
Fuse 8 (PDC)...................... 8W-10-8, 21
Fuse 9 (PDC)...................... 8W-10-8, 23
Fuse 10 (PDC)..................... 8W-10-8, 22
Fuse 11 (PDC)..................... 8W-10-8, 23
Fuse 12 (JB)........................ 8W-10-10
Fuse 12 (PDC)................... 8W-10-8, 9, 23
Fuse 13 (JB)........................ 8W-10-10
Component Page
Fuse 14 (JB)........................ 8W-10-10
Fuse B (PDC)................... 8W-10-8, 9, 24
Fuse C (PDC)..................... 8W-10-9, 24
Fuse E (PDC)..................... 8W-10-9, 24
Fuse F (PDC)..................... 8W-10-9, 24
Fuse G (PDC)..................... 8W-10-9, 25
Fuse H (PDC)..................... 8W-10-9, 26
Fuse I (PDC)...................... 8W-10-9, 26
Fuse J (PDC)...................... 8W-10-9, 27
Fuse K (PDC)............. 8W-10-9, 14, 17, 18, 19
Fuse L (PDC)..................... 8W-10-9, 27
Fuse Gen (PDC)................... 8W-10-8, 27
G201............................. 8W-10-22
Generator........................ 8W-10-8, 27
Headlamp Beam Select Switch........... 8W-10-25
Headlamp Switch.................. 8W-10-9, 24
High Note Horn..................... 8W-10-26
Horn Relay....................... 8W-10-9, 26
Ignition Coil........................ 8W-10-15
Ignition Coil 4 Pack................... 8W-10-16
Ignition Coil 6 Pack................... 8W-10-16
Ignition Switch................. 8W-10-8, 10, 22
Joint Connector No. 1.............. 8W-10-25, 26
Joint Connector No. 2........ 8W-10-8, 9, 11, 12, 14,
15, 16, 20, 21
Joint Connector No. 5................. 8W-10-22
Joint Connector No. 6............ 8W-10-13, 22, 26
Joint Connector No. 8................. 8W-10-22
Junction Block.................. 8W-10-8, 10, 13
Left Fog Lamp...................... 8W-10-25
Left Headlamp...................... 8W-10-24
Left Outboard Headlamp.......... 8W-10-9, 24, 25
Low Note Horn...................... 8W-10-26
Oxygen Sensor 1/1 Left Bank Up . . . 8W-10-17, 18, 19
Oxygen Sensor 1/1 Upstream............ 8W-10-17
Oxygen Sensor 1/2 Downstream.......... 8W-10-17
Oxygen Sensor 1/2 Left Bank Down....... 8W-10-19
Oxygen Sensor 1/2 Pre-Catalyst.......... 8W-10-18
Oxygen Sensor 1/3 Post-Catalyst......... 8W-10-18
Oxygen Sensor 2/1 Right Bank Up . . 8W-10-17, 18, 19
Oxygen Sensor 2/2 Right Bank Down...... 8W-10-19
Oxygen Sensor Downstream Relay..... 8W-10-18, 19
Power Distribution Center.... 8W-10-8, 9, 10, 11, 12,
13, 14, 2, 20, 21, 22, 23, 24, 25, 26, 27
Power Outlet...................... 8W-10-9, 27
Powertrain Control Module . . 8W-10-11, 12, 15, 16, 20
Quad High Beam Relay................ 8W-10-24
Right Fog Lamp..................... 8W-10-25
Right Headlamp..................... 8W-10-24
Right Outboard Headlamp......... 8W-10-9, 24, 25
Security Relay..................... 8W-10-9, 25
Trailer Tow Connector................. 8W-10-21
Trailer Tow Relay.................... 8W-10-21
Transmission Control Relay........... 8W-10-9, 26
Transmission Solenoid Assembly......... 8W-10-26
Turn Signal/Hazard Switch............. 8W-10-13
BR/BE8W-10 POWER DISTRIBUTION 8W - 10 - 1

8W-30 FUEL/IGNITION SYSTEM
Component Page
A/C Compressor Clutch Relay.... 8W-30-14, 38, 39
A/C High Pressure Switch.......... 8W-30-14, 39
A/C Low Pressure Switch.......... 8W-30-14, 39
A/C-Heater Control............... 8W-30-14, 39
Accelerator Pedal Position Sensor....... 8W-30-30
Airbag Control Module............ 8W-30-15, 40
Automatic Shut Down Relay..... 8W-30-3, 17, 18,
19, 22, 23, 24, 25, 26, 27, 28
Battery........................... 8W-30-35
Battery Temperature Sensor............ 8W-30-4
Brake Lamp Switch.............. 8W-30-8, 7, 37
Camshaft Position Sensor........... 8W-30-5, 32
Capacitor......................... 8W-30-28
Central Timer Module............. 8W-30-15, 40
Clockspring...................... 8W-30-7, 34
Controller Antilock Brake.... 8W-30-13, 15, 38, 40
Crankshaft Position Sensor............ 8W-30-13
Cummins Bus...................... 8W-30-29
Data Link Connector...... 8W-30-2, 15, 16, 40, 41
Daytime Running Lamp Module........ 8W-30-38
Engine Control Module . . 8W-30-3, 7, 29, 30, 31, 32,
33, 34, 35, 36, 37, 38, 39, 40, 41
Engine Coolant Temperature Sensor . . . 8W-30-9, 34
Engine Oil Pressure Sensor......... 8W-30-13, 33
EVAP/Purge Solenoid................ 8W-30-13
Fuel Heater........................ 8W-30-36
Fuel Heater Relay................... 8W-30-36
Fuel Injection Pump.............. 8W-30-31, 37
Fuel Injector No. 1............... 8W-30-23, 26
Fuel Injector No. 2............... 8W-30-24, 27
Fuel Injector No. 3............... 8W-30-23, 26
Fuel Injector No. 4............... 8W-30-24, 27
Fuel Injector No. 5............... 8W-30-23, 26
Fuel Injector No. 6............... 8W-30-24, 27
Fuel Injector No. 7............... 8W-30-23, 26
Fuel Injector No. 8............... 8W-30-24, 27
Fuel Injector No. 9.................. 8W-30-26
Fuel Injector No. 10................. 8W-30-27
Fuel Pump Module.................. 8W-30-12
Fuel Pump Relay......... 8W-30-3, 11, 12, 31, 37
Fuel Tank Module................... 8W-30-42
Fuel Transfer Pump................. 8W-30-34
Fuse 3 (PDC)............... 8W-30-2, 11, 29, 37
Fuse 6 (PDC)....................... 8W-30-3
Fuse 7 (PDC)...................... 8W-30-36
Fuse 9 (JB)................. 8W-30-2, 3, 11, 36
Fuse 11 (JB)................. 8W-30-13, 36, 39
Fuse 12 (JB).................... 8W-30-16, 41
Fuse K (PDC)........... 8W-30-17, 18, 19, 20, 22
Fusible Link....................... 8W-30-35
G100............................. 8W-30-12
G102.......................... 8W-30-36, 37Component Page
G105..................... 8W-30-2, 16, 20, 21
G107.......................... 8W-30-34, 36
G113 .......................... 8W-30-14, 34
G200.......................... 8W-30-16, 37
Generator...................... 8W-30-13, 38
Idle Air Control Motor................ 8W-30-9
Ignition Coil....................... 8W-30-25
Ignition Coil 4 Pack................. 8W-30-28
Ignition Coil 6 Pack................. 8W-30-28
Instrument Cluster............ 8W-30-15, 34, 40
Intake Air Heater................... 8W-30-35
Intake Air Heater Relay No. 1......... 8W-30-35
Intake Air Heater Relay No. 2......... 8W-30-35
Intake Air Temperature Sensor...... 8W-30-10, 32
Joint Connector No. 1....... 8W-30-4, 7, 8, 12, 36,
37, 38, 42
Joint Connector No. 2 . . . 8W-30-2, 3, 11, 17, 18, 19,
22, 23, 24, 25, 26, 27, 28, 29, 35, 37
Joint Connector No. 5............. 8W-30-16, 41
Joint Connector No. 7............. 8W-30-15, 40
Junction Block . . . 8W-30-2, 3, 11, 13, 16, 36, 39, 41
Leak Detection Pump................. 8W-30-8
Left Speed Control Switch............. 8W-30-7
Manifold Absolute Pressure Sensor . . . 8W-30-10, 33
Output Speed Sensor................. 8W-30-5
Overdrive Switch.................... 8W-30-6
Overhead Console................ 8W-30-15, 40
Oxygen Sensor 1/1 Left Bank Up.... 8W-30-18, 20,
21, 22
Oxygen Sensor 1/1 Upstream.......... 8W-30-17
Oxygen Sensor 1/2 Downstream........ 8W-30-17
Oxygen Sensor 1/2 Left Bank Down..... 8W-30-20
Oxygen Sensor 1/2 Pre- Catalyst........ 8W-30-21
Oxygen Sensor 1/3 Post- Catalyst....... 8W-30-21
Oxygen Sensor 2/1 Right Bank Up . . . 8W-30-18, 20,
21, 22
Oxygen Sensor 2/2 Right Bank Down.... 8W-30-20
Oxygen Sensor Downstream Relay . . . 8W-30-19, 21
Park/Neutral Position Switch....... 8W-30-13, 38
Power Distribution Center . . 8W-30-2, 3, 11, 17, 18,
19, 22, 23, 24, 25, 26, 27, 28, 29, 36, 37
Powertrain Control Module . . 8W-30-2, 3, 4, 5, 6, 7,
10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22,
23, 24, 25, 26, 27, 28, 36, 37, 38, 39, 40, 41, 42
PTO Switch..................... 8W-30-14, 34
Radio.......................... 8W-30-15, 40
Right Speed Control Switch............ 8W-30-7
Speed Control Servo.................. 8W-30-5
Throttle Position Sensor.............. 8W-30-14
Transmission Control Relay............ 8W-30-5
Transmission Solenoid Assembly . . . 8W-30-6, 14, 39
Water In Fuel Sensor................ 8W-30-34
BR/BE8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 1

Heater Diagnosis
3. Incorrect engine
coolant temperature.3. Check the performance and operation of the engine
cooling system including: thermostat, water pump, fan
drive, accessory drive belt, coolant flow (plugged radiator
or heater core, plugged or kinked coolant hoses), air flow
(missing or improperly installed radiator air seals or fan
shroud). Refer to Cooling for the procedures.
4. Blend door actuator
inoperative or defective.4. (Refer to Controls/Blend Door Actuator) in this group.
5. Blend door not
operating properly.5. Check for a damaged, obstructed or improperly
installed blend door or seals. (Refer to Controls/Blend
Door Actuator) in this group.
6. Insufficient air flow
through heater housing.6. Remove foreign material or obstructions from cowl air
intake.
7. Improper blower motor
operation.7. (Refer to Distribution/Blower Motor/ Diagnosis and
Testing) in this group.
STANDARD PROCEDURE - DIODE
REPLACEMENT
(1) Disconnect the battery negative cable and iso-
late it.
(2) Locate the diode in the harness, and remove
the protective covering.
(3) Remove the diode from the harness, pay atten-
tion to the current flow direction (Fig. 3).
(4) Remove the insulation from the wires in the
harness. Only remove enough insulation to solder in
the new diode.
(5) Install the new diode in the harness, making
sure current flow is correct. If necessary refer to the
appropriate wiring diagram for current flow.
(6) Solder the connection together using rosin core
type solder only.Do not use acid core solder.(7) Tape the diode to the harness using electrical
tape making, sure the diode is completely sealed
from the elements.
(8) Re-connect the battery negative cable, and test
affected systems.
SPECIFICATIONS
A/C APPLICATION TABLE
Item Description Notes
Vehicle BR/BE - Ram
Pickup
System R134a w/orifice
tube
Compressor Sanden SD7H15 SP-20 PAG oil
Freeze±up
ControlA/C Low
Pressure Switchaccumulator
mounted
Low psi Control opens < 22-24
psi resets >
37-43 psi
High psi Control switch - opens >
450 - 490 psi,
resets < 270 -
330 psimounted on
discharge line,
near
compressor
A/C Heater
Control Headmanual type
Mode Door vacuum actuator
Blend Door electric actuator
Recirculation
Doorvacuum actuator
Fig. 3 DIODE IDENTIFICATION
1 - CURRENT FLOW
2 - BAND AROUND DIODE INDICATES CURRENT FLOW
3 - DIODE AS SHOWN IN THE DIAGRAMS
BR/BEHEATING & AIR CONDITIONING 24 - 7
HEATING & AIR CONDITIONING (Continued)

CONTROLS
TABLE OF CONTENTS
page page
CONTROLS
DIAGNOSIS AND TESTING.................10
DIAGNOSIS AND TESTING - VACUUM
SYSTEM.............................10
A/C COMPRESSOR CLUTCH
DESCRIPTION..........................11
OPERATION............................13
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - A/C
COMPRESSOR CLUTCH COIL............13
STANDARD PROCEDURE
STANDARD PROCEDURE - A/C
COMPRESSOR CLUTCH BREAK-IN........13
REMOVAL..............................13
INSPECTION............................15
INSTALLATION..........................15
A/C COMPRESSOR CLUTCH RELAY
DESCRIPTION..........................17
OPERATION............................17
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - A/C
COMPRESSOR CLUTCH RELAY...........17
REMOVAL..............................18
INSTALLATION..........................18
A/C-HEATER CONTROL
DESCRIPTION..........................18
OPERATION............................18
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - A/C HEATER
CONTROL............................18
REMOVAL..............................19
INSTALLATION..........................19
A/C HIGH PRESSURE SWITCH
DESCRIPTION..........................20
OPERATION............................20
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - A/C HIGH
PRESSURE SWITCH....................20
REMOVAL..............................20
INSTALLATION..........................20
A/C LOW PRESSURE SWITCH
DESCRIPTION..........................21
OPERATION............................21DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - A/C LOW
PRESSURE SWITCH....................21
REMOVAL..............................21
INSTALLATION..........................21
BLOWER MOTOR RELAY
DESCRIPTION..........................22
OPERATION............................22
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - BLOWER
MOTOR RELAY........................22
REMOVAL..............................23
INSTALLATION..........................23
BLOWER MOTOR RESISTOR BLOCK
DESCRIPTION..........................23
OPERATION............................23
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - BLOWER
MOTOR RESISTOR BLOCK...............23
REMOVAL..............................24
INSTALLATION..........................24
BLOWER MOTOR SWITCH
DESCRIPTION..........................24
OPERATION............................24
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - BLOWER
MOTOR SWITCH.......................25
REMOVAL..............................25
BLEND DOOR ACTUATOR
REMOVAL..............................25
INSTALLATION..........................25
MODE DOOR ACTUATOR
REMOVAL..............................26
INSTALLATION..........................27
RECIRCULATION DOOR ACTUATOR
REMOVAL..............................27
INSTALLATION..........................28
VACUUM CHECK VALVE
DESCRIPTION..........................28
OPERATION............................28
REMOVAL..............................29
INSTALLATION..........................29
BR/BECONTROLS 24 - 9

PLUMBING
TABLE OF CONTENTS
page page
PLUMBING
DESCRIPTION..........................40
OPERATION............................41
WARNING..............................42
CAUTION..............................42
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - REFRIGERANT
SYSTEM LEAKS.......................43
STANDARD PROCEDURE
STANDARD PROCEDURE - A/C LINE
COUPLERS...........................44
STANDARD PROCEDURE - REFRIGERANT
SYSTEM SERVICE EQUIPMENT...........45
STANDARD PROCEDURE - REFRIGERANT
RECOVERY...........................45
STANDARD PROCEDURE - REFRIGERANT
SYSTEM EVACUATE....................46
STANDARD PROCEDURE - REFRIGERANT
SYSTEM CHARGE......................46
SPECIFICATIONS........................46
A/C COMPRESSOR
DESCRIPTION..........................46
OPERATION............................46
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - A/C
COMPRESSOR........................47
REMOVAL..............................47
INSTALLATION..........................48
A/C CONDENSER
DESCRIPTION..........................49
OPERATION............................49
REMOVAL..............................49
INSTALLATION..........................50
SUCTION AND DISCHARGE LINE
REMOVAL..............................51
INSTALLATION..........................52LIQUID LINE
REMOVAL..............................52
INSTALLATION..........................52
A/C EVAPORATOR
DESCRIPTION..........................53
OPERATION............................53
REMOVAL..............................53
INSTALLATION..........................53
A/C ORIFICE TUBE
DESCRIPTION..........................54
OPERATION............................54
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - FIXED
ORIFICE TUBE.........................54
REMOVAL..............................54
INSTALLATION..........................54
ACCUMULATOR
DESCRIPTION..........................55
OPERATION............................55
REMOVAL..............................55
INSTALLATION..........................55
HEATER CORE
DESCRIPTION..........................56
OPERATION............................56
REMOVAL..............................56
INSTALLATION..........................56
REFRIGERANT
DESCRIPTION..........................56
OPERATION............................57
REFRIGERANT OIL
DESCRIPTION..........................57
OPERATION............................57
STANDARD PROCEDURE
STANDARD PROCEDURE - REFRIGERANT
OIL LEVEL............................57
PLUMBING
DESCRIPTION - A/C LINE COUPLERS
Spring-lock type refrigerant line couplers are used
to connect many of the refrigerant lines and other
components to the refrigerant system. These couplers
require a special tool for disengaging the two coupler
halves.
DESCRIPTION- REFRIGERANT LINES
The refrigerant lines and hoses are used to carry
the refrigerant between the various air conditioning
system components. A barrier hose design with a
nylon tube, which is sandwiched between rubber lay-
ers, is used for the R-134a air conditioning system on
this vehicle. This nylon tube helps to further contain
the R-134a refrigerant, which has a smaller molecu-
lar structure than R-12 refrigerant. The ends of the
refrigerant hoses are made from lightweight alumi-
num or steel, and commonly use braze-less fittings.
24 - 40 PLUMBINGBR/BE

OPERATION
R-134a refrigerant is not compatible with R-12
refrigerant in an air conditioning system. Even a
small amount of R-12 added to an R-134a refrigerant
system will cause compressor failure, refrigerant oil
sludge or poor air conditioning system performance.
In addition, the PolyAlkylene Glycol (PAG) synthetic
refrigerant oils used in an R-134a refrigerant system
are not compatible with the mineral-based refriger-
ant oils used in an R-12 refrigerant system.
R-134a refrigerant system service ports, service
tool couplers and refrigerant dispensing bottles have
all been designed with unique fittings to ensure that
an R-134a system is not accidentally contaminated
with the wrong refrigerant (R-12). There are also
labels posted in the engine compartment of the vehi-
cle and on the compressor identifying to service tech-
nicians that the air conditioning system is equipped
with R-134a.
REFRIGERANT OIL
DESCRIPTION
The refrigerant oil used in R-134a refrigerant sys-
tems is a synthetic-based, PolyAlkylene Glycol (PAG),
wax-free lubricant. Mineral-based R-12 refrigerant
oils are not compatible with PAG oils, and should
never be introduced to an R-134a refrigerant system.
There are different PAG oils available, and each
contains a different additive package. The SD7H15
compressor used in this vehicle is designed to use an
SP-20 PAG refrigerant oil. Use only refrigerant oil of
this same type to service the refrigerant system.
OPERATION
After performing any refrigerant recovery or recy-
cling operation, always replenish the refrigerant sys-
tem with the same amount of the recommended
refrigerant oil as was removed. Too little refrigerant
oil can cause compressor damage, and too much can
reduce air conditioning system performance.
PAG refrigerant oil is much more hygroscopic than
mineral oil, and will absorb any moisture it comes
into contact with, even moisture in the air. The PAG
oil container should always be kept tightly capped
until it is ready to be used. After use, recap the oil
container immediately to prevent moisture contami-
nation.
STANDARD PROCEDURE - REFRIGERANT OIL
LEVEL
When an air conditioning system is assembled at
the factory, all components except the compressor are
refrigerant oil free. After the refrigerant system has
been charged and operated, the refrigerant oil in the
compressor is dispersed throughout the refrigerant
system. The accumulator, evaporator, condenser, and
compressor will each retain a significant amount of
the needed refrigerant oil.
It is important to have the correct amount of oil in
the refrigerant system. This ensures proper lubrica-
tion of the compressor. Too little oil will result in
damage to the compressor. Too much oil will reduce
the cooling capacity of the air conditioning system.
It will not be necessary to check the oil level in the
compressor or to add oil, unless there has been an oil
loss. An oil loss may occur due to a rupture or leak
from a refrigerant line, a connector fitting, a compo-
nent, or a component seal. If a leak occurs, add 30
milliliters (1 fluid ounce) of refrigerant oil to the
refrigerant system after the repair has been made.
Refrigerant oil loss will be evident at the leak point
by the presence of a wet, shiny surface around the
leak.
Refrigerant oil must be added when a accumulator,
evaporator coil, or condenser are replaced. See the
Refrigerant Oil Capacities chart. When a compressor
is replaced, the refrigerant oil must be drained from
the old compressor and measured. Drain all of the
refrigerant oil from the new compressor, then fill the
new compressor with the same amount of refrigerant
oil that was drained out of the old compressor.
Refrigerant Oil Capacities
Component ml fl oz
A/C System 210 6.2
Accumulator 60 2
Condenser 30 1
Evaporator 60 2
Compressordrain and measure
the oil from the old
compressor - see
text.
BR/BEPLUMBING 24 - 57
REFRIGERANT (Continued)

ABS - DESCRIPTION, BRAKES...........5-35
ABS - OPERATION, BRAKES.............5-36
ABS BRAKE SYSTEM - STANDARD
PROCEDURE, BLEEDING................5-36
ABS INDICATOR - DESCRIPTION.........8J-14
ABS INDICATOR - OPERATION..........8J-14
A/C APPLICATION TABLE,
SPECIFICATIONS......................24-7
A/C COMPRESSOR - DESCRIPTION......24-46
A/C COMPRESSOR - DIAGNOSIS AND
TESTING...........................24-47
A/C COMPRESSOR - INSTALLATION......24-48
A/C COMPRESSOR - OPERATION........24-46
A/C COMPRESSOR - REMOVAL.........24-47
A/C COMPRESSOR CLUTCH -
DESCRIPTION.......................24-11
A/C COMPRESSOR CLUTCH -
INSPECTION........................24-15
A/C COMPRESSOR CLUTCH -
INSTALLATION.......................24-15
A/C COMPRESSOR CLUTCH -
OPERATION.........................24-13
A/C COMPRESSOR CLUTCH - REMOVAL . . 24-13
A/C COMPRESSOR CLUTCH BREAK-IN -
STANDARD PROCEDURE...............24-13
A/C COMPRESSOR CLUTCH COIL -
DIAGNOSIS AND TESTING.............24-13
A/C COMPRESSOR CLUTCH RELAY -
DESCRIPTION.......................24-17
A/C COMPRESSOR CLUTCH RELAY -
DIAGNOSIS AND TESTING...............24-17
A/C COMPRESSOR CLUTCH RELAY -
INSTALLATION.......................24-18
A/C COMPRESSOR CLUTCH RELAY -
OPERATION.........................24-17
A/C COMPRESSOR CLUTCH RELAY -
REMOVAL..........................24-18
A/C CONDENSER - DESCRIPTION........24-49
A/C CONDENSER - INSTALLATION.......24-50
A/C CONDENSER - OPERATION..........24-49
A/C CONDENSER - REMOVAL...........24-49
A/C EVAPORATOR - DESCRIPTION.......24-53
A/C EVAPORATOR - INSTALLATION......24-53
A/C EVAPORATOR - OPERATION.........24-53
A/C EVAPORATOR - REMOVAL..........24-53
A/C HEATER CONTROL - DIAGNOSIS
AND TESTING.......................24-18
A/C HIGH PRESSURE SWITCH -
DESCRIPTION.......................24-20
A/C HIGH PRESSURE SWITCH -
DIAGNOSIS AND TESTING.............24-20
A/C HIGH PRESSURE SWITCH -
INSTALLATION.......................24-20
A/C HIGH PRESSURE SWITCH -
OPERATION.........................24-20
A/C HIGH PRESSURE SWITCH -
REMOVAL..........................24-20
A/C LINE COUPLERS - DESCRIPTION.....24-40
A/C LINE COUPLERS - OPERATION......24-41
A/C LINE COUPLERS - STANDARD
PROCEDURE........................24-44
A/C LOW PRESSURE SWITCH -
DESCRIPTION.......................24-21
A/C LOW PRESSURE SWITCH -
DIAGNOSIS AND TESTING.............24-21
A/C LOW PRESSURE SWITCH -
INSTALLATION.......................24-21
A/C LOW PRESSURE SWITCH -
OPERATION
.........................24-21
A/C LOW PRESSURE SWITCH -
REMOVAL
..........................24-21
A/C ORIFICE TUBE - DESCRIPTION
.......24-54
A/C ORIFICE TUBE - INSTALLATION
......24-54
A/C ORIFICE TUBE - OPERATION
........24-54
A/C ORIFICE TUBE - REMOVAL
..........24-54
A/C PERFORMANCE - DIAGNOSIS AND
TESTING
............................24-2
ACCELERATOR PEDAL - INSTALLATION
. . . 14-37
ACCELERATOR PEDAL - REMOVAL
.......14-36
ACCELERATOR PEDAL POSITION
SENSOR - DESCRIPTION
...............14-95
ACCELERATOR PEDAL POSITION
SENSOR - INSTALLATION
..............14-97
ACCELERATOR PEDAL POSITION
SENSOR - OPERATION
................14-95
ACCELERATOR PEDAL POSITION
SENSOR - REMOVAL
..................14-95ACCESSORY DRIVE BELT - DIAGNOSIS
AND TESTING................7-24,7-27,7-30
ACCUMULATOR - DESCRIPTION.........24-55
ACCUMULATOR - DESCRIPTION . . 21-149,21-319
ACCUMULATOR - INSPECTION . . . 21-150,21-320
ACCUMULATOR - INSTALLATION........24-55
ACCUMULATOR - OPERATION..........24-55
ACCUMULATOR - OPERATION....21-150,21-320
ACCUMULATOR - REMOVAL............24-55
A/C-HEATER CONTROL - DESCRIPTION . . . 24-18
A/C-HEATER CONTROL - INSTALLATION . . . 24-19
A/C-HEATER CONTROL - OPERATION.....24-18
A/C-HEATER CONTROL - REMOVAL......24-19
ACTUATION TEST MODE - DESCRIPTION,
CIRCUIT.............................25-2
ACTUATOR - INSTALLATION, BLEND
DOOR.............................24-25
ACTUATOR - INSTALLATION, HEAT/
DEFROST DOOR.....................24-27
ACTUATOR - INSTALLATION, INSIDE
HANDLE.......................23-72,23-80
ACTUATOR - INSTALLATION, PANEL/
DEFROST DOOR.....................24-27
ACTUATOR - INSTALLATION,
RECIRCULATION DOOR................24-28
ACTUATOR - REMOVAL, BLEND DOOR....24-25
ACTUATOR - REMOVAL, HEAT/DEFROST
DOOR.............................24-26
ACTUATOR - REMOVAL, INSIDE HANDLE . 23-72,
23-80
ACTUATOR - REMOVAL, PANEL/DEFROST
DOOR.............................24-26
ACTUATOR - REMOVAL, RECIRCULATION
DOOR.............................24-27
ADAPTER - INSTALLATION, DEFROSTER
AND DEMISTER DUCT.................24-33
ADAPTER - REMOVAL, DEFROSTER AND
DEMISTER DUCT.....................24-33
ADAPTER BRACKET - INSTALLATION,
CAB CHASSIS.......................13-10
ADAPTER BRACKET - REMOVAL, CAB
CHASSIS...........................13-10
ADAPTER HOUSING SEAL - NV4500 -
INSTALLATION.......................21-42
ADAPTER HOUSING SEAL - NV4500 -
REMOVAL..........................21-42
ADAPTER HOUSING SEAL - NV5600 -
INSTALLATION.......................21-85
ADAPTER HOUSING SEAL - NV5600 -
REMOVAL..........................21-85
ADDING ADDITIONAL COOLANT -
STANDARD PROCEDURE................7-16
ADDITIONAL COOLANT - STANDARD
PROCEDURE, ADDING..................7-16
ADDITIVES - STANDARD PROCEDURE,
COOLANT SELECTION..................7-17
ADHESIVE LOCATIONS, SPECIFICATIONS
- STRUCTURAL......................23-44
ADJUSTER - INSTALLATION, SEAT BELT
TURNING LOOP.....................8O-29
ADJUSTER - INSTALLATION, SEAT
TRACK............................23-143
ADJUSTER - REMOVAL, SEAT BELT
TURNING LOOP.....................8O-29
ADJUSTER - REMOVAL, SEAT TRACK....23-143
ADJUSTER ASSEMBLY - INSTALLATION,
ROCKER ARM........................9-26
ADJUSTER ASSEMBLY - REMOVAL,
ROCKER ARM........................9-26
ADJUSTER ASSY - CLEANING, ROCKER
ARM ..............................9-146
ADJUSTER ASSY - DESCRIPTION,
ROCKER ARM.......................9-145
ADJUSTER ASSY - INSPECTION,
ROCKER ARM.......................9-146
ADJUSTER ASSY - INSTALLATION,
ROCKER ARM...................9-148,9-84
ADJUSTER ASSY - REMOVAL, ROCKER
ARM ..........................9-145,9-84
ADJUSTER KNOB - INSTALLATION,
TURNING LOOP HGT
.................8O-30
ADJUSTER KNOB - REMOVAL, TURNING
LOOP HGT
..........................8O-30
ADJUSTMENT - STANDARD
PROCEDURE, COMPASS VARIATION
......8M-4
ADJUSTMENT, ADJUSTMENTS
. . . 23-101,23-102,
23-103
ADJUSTMENT, ADJUSTMENTS
...........5-30ADJUSTMENT, ADJUSTMENTS...........13-2
ADJUSTMENT, ADJUSTMENTS . . . 21-208,21-380
ADJUSTMENT AND VERIFICATION -
STANDARD PROCEDURE, VALVE LASH....9-141
ADJUSTMENT, BANDS..........21-151,21-321
ADJUSTMENT, CARGO DOOR...........23-78
ADJUSTMENT, CENTER BEARING..........3-8
ADJUSTMENT, FRONT DOOR FORE/AFT . . . 23-69
ADJUSTMENT, FRONT DOOR IN/OUT.....23-70
ADJUSTMENT, FRONT DOOR LATCH......23-73
ADJUSTMENT, FRONT DOOR UP/DOWN . . . 23-70
ADJUSTMENT, PARKING BRAKE SHOES....5-33
ADJUSTMENT, SHIFT LEVER.....21-463,21-500
ADJUSTMENTS - ADJUSTMENT . . 23-101,23-102,
23-103
ADJUSTMENTS - ADJUSTMENT..........5-30
ADJUSTMENTS - ADJUSTMENT..........13-2
ADJUSTMENTS - ADJUSTMENT . . 21-208,21-380
ADJUSTMENTS, FOG LAMP UNIT........8L-13
ADJUSTMENTS, FRONT AXLE - 248FBI....3-19
ADJUSTMENTS, GEAR.................19-18
ADJUSTMENTS, HEADLAMP UNIT.......8L-21
ADJUSTMENTS, REAR AXLE - 248RBI.....3-51
ADJUSTMENTS, REAR AXLE - 267RBI.....3-83
ADJUSTMENTS, REAR AXLE - 286RBI....3-112
ADJUSTMENTS, TRANSMISSION
THROTTLE VALVE CABLE.........21-210,21-382
ADJUSTMENTS, VALVE BODY....21-257,21-428
AIR BLEED - STANDARD PROCEDURE....14-61
AIR CLEANER ELEMENT - INSTALLATION . . 9-130
AIR CLEANER ELEMENT - REMOVAL.....9-129
AIR CONDITIONER - DESCRIPTION,
HEATER .............................24-1
AIR CONDITIONER - OPERATION,
HEATER .............................24-1
AIR CONDITIONING - INSTALLATION,
WATER PUMP BYPASS HOSE WITH.......7-76
AIR CONDITIONING - INSTALLATION,
WATER PUMP BYPASS HOSE
WITHOUT............................7-77
AIR CONDITIONING - REMOVAL, WATER
PUMP BYPASS HOSE WITH.............7-73
AIR CONDITIONING - REMOVAL, WATER
PUMP BYPASS HOSE WITHOUT..........7-76
AIR CONTROL MOTOR - DESCRIPTION,
IDLE...............................14-40
AIR CONTROL MOTOR - OPERATION,
IDLE...............................14-40
AIR COOLER AND PLUMBING -
CLEANING, CHARGE..................11-19
AIR COOLER AND PLUMBING -
DESCRIPTION, CHARGE...............11-18
AIR COOLER AND PLUMBING -
INSPECTION, CHARGE.................11-19
AIR COOLER AND PLUMBING -
INSTALLATION, CHARGE...............11-20
AIR COOLER AND PLUMBING -
OPERATION, CHARGE.................11-18
AIR COOLER AND PLUMBING -
REMOVAL, CHARGE..................11-18
AIR COOLER SYSTEM - LEAKS -
DIAGNOSIS AND TESTING, CHARGE......11-18
AIR DAM - INSTALLATION, FRONT........13-2
AIR DAM - REMOVAL, FRONT...........13-2
AIR EXHAUSTER - INSTALLATION.......23-77
AIR EXHAUSTER - REMOVAL...........23-77
AIR HEATER - DESCRIPTION, INTAKE....14-104
AIR HEATER - INSTALLATION, INTAKE . . . 14-105
AIR HEATER - OPERATION, INTAKE.....14-104
AIR HEATER - REMOVAL, INTAKE.......14-104
AIR HEATER RELAY - DESCRIPTION,
INTAKE............................14-105
AIR HEATER RELAY - INSTALLATION,
INTAKE............................14-106
AIR HEATER RELAY - OPERATION,
INTAKE............................14-105
AIR HEATER RELAY - REMOVAL, INTAKE . 14-106
AIR IN FUEL SYSTEM - DIAGNOSIS AND
TESTING...........................14-60
AIR INJECTION PUMP - DESCRIPTION....25-29
AIR INJECTION PUMP - DIAGNOSIS AND
TESTING...........................25-29
AIR INJECTION PUMP - INSTALLATION . . . 25-30
AIR INJECTION PUMP - OPERATION
.....25-29
AIR INJECTION PUMP - REMOVAL
.......25-30
AIR INJECTION SYSTEM - DESCRIPTION
. . 25-26
AIR INJECTION SYSTEM - OPERATION
....25-28
AIR INJECTION SYSTEM - TORQUE
......25-29
BR/BEINDEX 1
Description Group-Page Description Group-Page Description Group-Page